tires DODGE TRUCK 1993 Service Repair Manual

GROUP TAB LOCATOR

Introduction

0
Lubrication
and
Maintenance
2
Front Suspension
and
Axle

3
Rear Suspension
and
Axles

5
Brakes

6
Clutch
7
Cooling System

8
Electrical

9
Engines
11
Exhaust System
and
Intake
Manifold

13
Frame
and Bumpers

14
Fuel
System

16
Propeller Shafts

19
Steering

21
Transmission
and
Transfer Case

22
Wheels and Tires

23
Body Components

24
Heating
and Air
Conditioning

25
Emission Control Systems Component and System Index
Service Manual Comment Forms (Rear
of
Manual)

2 INTRODUCTION

•
MFD
BY
GAWR
FRONT
GAWR REAR
CHRYSLER

CORPORATION

DATE
OF MFR

GVWR

WITH
TIRES
WITH
TIRES
RIMS
AT

RIMS
AT
PSI
COLD

PSI
COLD
THIS
VEHICLE CONFORMS
TO
ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY

STANDARDS
IN
EFFECT ON
THE
DATE
OF
MANUFACTURE SHOWN ABOVE.

SINGLE
DUAL
MDH:
BAR
CODE
VEHICLE MADE
IN

4648503
J9HN-25

Fig. 1 Vehicle Safety Certification Label
The Vehicle Identification Number is also im­
printed on the:
• Body Code Plate
• Equipment Identification Plate
• Vehicle Safety Certification Label
• And on a frame rail.

VEHICLE CODE PLATE
A metal vehicle code plate (Fig. 2) is attached to

top,
right side of cowl below cowl grille. There can be a maximum of seven rows of vehicle information im­
printed on the plate. The information should be read
from left to right, starting with line 1 at the bottom
of the plate up to line 7 (as applicable) at the top of
the code plate. Refer to the decoding chart to decode lines 1
through 3.
Lines 4 through 7 on the plate are imprinted in se­
quence according to the following descriptions:
• 3-character sales code • 3-digit numerical code
• 6-digit SEC code If there is not enough space left in the row for all
of the 6-digit SEC code:
• The unused space will remain blank
• The code will be listed in the next row.
The last nine positions of row 7 will contain a
2-digit code and a 6-digit serial number.
The last code on a vehicle code plate will be fol­
lowed by the imprinted word END. When two plates
are required, the last available spaces on the first
plate will be imprinted with the letters CTD (for con­ tinued).
When a second vehicle code plate is necessary, the
first four spaces on each row will not be used because of the plate overlap.
To retrieve information from a vehicle code plate:
• Illuminate the plate with a shop light
• View the plate via the cowl grille slots
• Record the needed coded information.

ENGINE AND TRANSMISSION/TRANSFER CASE

IDENTIFICATION
Refer to Group 9—Engines for all engine identifi­
cation data. Refer to Group 21—Transmissions for all transmis­
sion/transfer case identification data.
VEHICLE IDENTIFICATION NUMBER (VIN) DECODING
Country

1
=
United States
2
=
Canada

3
=
Mexico Vehicle Type
4
=
Multipurpose
Passenger

5
=
Bus
6
=
Incomplete
7
=
Truck
GVWR
and

Hydraulic Brakes
0001 3001
4001
5001 6001
7001 8001
9001

10,001

Bus
or I
3000
4000
5000 6000
7000 8000
9000

10,000
14,000

nc.
Truck Line

E
=
Ramcharger
4x2
Chassis
Cab
4x2

Pickup
4x2

M
=
Ramcharger
4x4
Chassis
Cab
4x2
Pickup
4x4
Engines

X
=
3.9L
(MPI)

Y = 5.2L
(MPI)

Z
=
5.9L
(EFI)

5
=
5.9L HDC

8
=
5.9L Turbo Diesel Sequential
Serial Number

Six
Digit Numbers

Series

0 =
150S Job Rated
1
= 150
Job Rated
2
= 250
Job Rated

3
= 350
Job Rated
Body

3
=
Club Cab 6
=
Conventional Cab
9
=
Sport
Utility
2 DR
Plant Location

S
=
Dodge City
M
=
Lago
Alberto J931N-18

•
• —
LUiRICATlON
AND
MAINTENANCE
0 - 1
CONTENTS

page
page

CHASSIS
AND
BODY
28
ENGINE MAINTENANCE
14
DRIVETRAIN
.,,, 22
GENERAL INFORMATION
1

GENERAL
INFORMATION INDEl

page

Classification
of
Lubricants
. 3

Components
Requiring
No
Lubrication
4

Fuel Requirements
. 2
Introduction
1

Lubrication
and
Replacement Parts Recommendation
3
page

Routine Maintenance
2

Starting
Assistance (Jump Starting)
9

Vehicle
Lifting
Recommendations
............ 10

Vehicle Noise
Control
2

Vehicle Towing Recommendations
11

INTRODUCTION
Lubrication and maintenance is divided into re­
quired and recommended service tasks. The required service tasks must be completed to verify the emis­
sion controls function correctly. The recommended
service tasks should be completed to maintain safety
and durability. This information will assist the service personnel
in providing maximum protection for each owner's
vehicle. Conditions can vary with individual driving habits.
It is necessary to schedule maintenance as a time in­
terval as well as a distance interval. It is the owner's responsibility to determine the ap­
plicable driving condition. Also to have the vehicle serviced according to the maintenance schedule, and
to pay for the necessary parts and labor. Vehicles with a Gross Vehicle Weight Rating
(GVWR) of 3 855 kg (8,500 lbs.) or less must conform
to light duty emission standards. Vehicles with a Gross Vehicle Weight Rating (GVWR) of 3 856 kg
(8,501 lbs.) or more must conform to heavy duty
emission standards. The GVWR for each vehicle is listed on the Safety
Certification Label. This label is affixed to the driver
side door pillar (Fig. 1).
Additional maintenance and lubrication informa­
tion is listed in the Owner's Manual.
Mm
rv
CHRYSLER
DATE
OF MFR
MFD BY CORPORATION
GVWR
GAWR FRONT
GAWR REAR
WITH
TIRES

WITH
TIRES
RIMS
AT

RIMS
AT

PSI
COLD

PSI
COLD THIS VEHICLE CONFORMS
TO
ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY

STANDARDS
IN
EFFECT ON
THE
DATE
OF
MANUFACTURE SHOWN ABOVE.

SINGLE
DUAL

BAR
CODE

VEHICLE MADE
IN

4648503
J9UN-25

Fig. 1 Vehicle Safety
Certification
Label

SEVERE DRIVING
CONDITIONS
Vehicles subjected to severe driving conditions
should decrease the interval between component
maintenance. Severe driving conditions are defined
as:

• Frequent short trip driving less than 24 km (15
miles)
• Frequent driving in dusty conditions
• Trailer towing
• Extensive engine idling
• Sustained high speed operation
• Desert operation
• Frequent starting and stopping
• Cold climate operation

LUBRICATION
AND
MAINTENANCE

0 - 2
LUBRICATION
AND
MAINTENANCE

• Commercial service
When a vehicle is continuously subjected to severe
driving conditions, lubricate:
• Body components
• All the driveline coupling joints
• Steering linkage More often than normal driving conditions

DUSTY
AREAS
With this type of severe driving condition, special
care should be given to the:
• Engine air cleaner filter
• PCV filter
• Crankcase ventilation system
• Brake booster control valve air filter. Verify that the filters and the associated compo­
nents are clean. Also verify that they are functioning
effectively. This will minimize the amount of abra­ sive particles that enter the engine.

OFF-ROAD
(4WD)
OPERATION
After off-road (4WD) operation, inspect the under­
side of the vehicle. Inspect the:
• Tires
• Body structure
• Steering components
• Suspension components • Exhaust system
• Threaded fasteners

HARSH
SURFACE ENVIRONMENTS
After extended operation in harsh environments,
the brake drums, brake linings, and rear wheel bear­ ings should be inspected and cleaned. This will pre­
vent wear and erratic brake action.

ROUTINE MAINTENANCE
The following routine maintenance is recommended
on a monthly basis: TIRES—Inspect the tires for unusual wear/damage.
Determine if the inflation pressure is adequate for
the vehicle load. BATTERY—Inspect and clean the terminals.
Tighten the terminals if necessary. FLUIDS—Determine if the component fluid levels
are acceptable. Add fluid, if necessary. LIGHTS/ELECTRICAL—Test all the electrical sys­
tems in the vehicle for proper operation. It is also recommended that the engine oil and the
washer fluid level be determined at each fuel fill-up.

VEHICLE
NOISE CONTROL
Vehicles with a GVWR of 4 535 kg (10,000 lbs), or
more, are required to comply with Federal Exterior Noise Regulations (Fig. 2).
VEHICLE
NOISE
EMISSION
CONTROL INFORMATION

DATE
OF
VEHICLE
MANUFACTURE

THIS
VEHICLE CONFORMS
TO
U.S. EPA REGULATIONS FOR NOISE EMISSION

APPLICABLE
TO
MEDIUM
AND HEAVY
DUTY
TRUCKS. THE
FOLLOWING
ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY THE NOISE CONTROL ACT
OF 1972. (A) THE
REMOVAL
OR

RENDERING
INOPERATIVE, OTHER
THAN
FOR
PURPOSES
OF
MAINTENANCE,
REPAIR.
OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR ELEMENT OF
DESIGN
(LISTED
IN
THE
OWNERS
MANUAL)
INCORPORATED
INTO
THIS
VEHICLE
IN COMPLIANCE
WITH
THE NOISE CONTROL
ACT:
(B) THE
USE
OF
THIS
VEHICLE
AFTER SUCH DEVICE
OR
ELEMENT
OF
DESIGN HAS BEEN REMOVED
OR
RENDERED
INOPERATIVE.

PU626D

Fig.
2 Vehicle
Noise
Emission
Control Information
Label

UNAUTHORIZED
DEFEAT
OF
NOISE
CONTROL COMPONENTS
Federal law prohibits removal, altering or other­
wise defeating any noise control component. This in­
cludes before or after the vehicle is in use. Federal
law also prohibits the use of a vehicle after a noise
control component is defeated.

REQUIRED MAINTENANCE/SERVICE
FOR
NOISE
CONTROL

The following maintenance is required after each
6-month or 9 600 km (6,000 miles) interval. This will
ensure that the vehicle noise control components are
operating properly.

EXHAUST SYSTEM
Inspect exhaust system for exhaust leaks and dam­
aged components. The exhaust hangers, clamps and
U-bolts should be attached and in good condition.
Burned or ruptured mufflers, damaged exhaust pipes should be replaced. Refer to Group 11—Exhaust Sys­
tem/Intake Manifold for service information.

AIR
FILTER
HOUSING/CANISTER
Inspect the air filter assembly for proper fit. Verify
the cover is securely attached to the housing/canis­
ter. Inspect all the air filter housing hoses for con­ nections. The gasket between the air filter housing and throttle body must be in good condition. The air
filter element should be clean and serviced according
to the maintenance schedule.

FUEL
REQUIREMENTS
GASOLINE
ENGINES
All engines require the use of unleaded gasoline to
reduce the effects of lead to the environment. Also unleaded fuel is necessary to prevent damage to the
catalytic converter/02 sensor. The fuel must have a
minimum octane rating of 87 based on the (R + M)/2
calculation method.

0
- 28
LUBRICATION
AND
MAINTENANCE

•
CHASSIS AND BODY

page

Body
Component Mechanisms
32
Front
Suspension
Ball
Joints
28

Front
Wheel Bearings
29

Headlamps
32

Lower
and
Upper Suspension
Arm
Bushings
.... 30

Manual
Steering Gear
28

STEERING
LINKAGE

INSPECTION When
a
vehicle
is
raised
for
maintenance under
the vehicle,
all
steering components should
be
checked.
LUBRICATION SCHEDULE The steering linkage
is
lubricated with
a
chassis
lubricant. However,
it is
recommended that
the
link­
age
be
inspected
and
lubricated after each:
•
24 000 km
(15,000 miles) interval
or
every
6

months,
for 2WD
vehicles subject
to the
LIGHT
DUTY CYCLE Maintenance Schedule
•
9 600 km
(6,000 miles) interval
or
every
6
months,
for
2WD
vehicles subject
to the
HEAVY DUTY
CY­
CLE Maintenance Schedule
•
12 000 km
(7,500 miles) interval
or
every
6

months,
for 4WD
vehicles subject
to the
LIGHT DUTY CYCLE Maintenance Schedule
•
9 600 km
(6,000 miles) interval
or
every
6
months,
for
4WD
vehicles subject
to the
HEAVY DUTY
CY­
CLE Maintenance Schedule.
LUBRICATION (1) Inspect
the
steering linkage
for
looseness
and

excessive wear. (2) Replace,
all
ruptured seals
and
damaged steer­
ing linkage components. Damaged seals should
be re­

placed
to
prevent leakage
and
contamination
of the
lubricant.

CAUTION:
Use
care
to
prevent lubricant from
con­

tacting
the
brake rotors.

(3) Lubricate
the
steering linkage:
• Clean
the
Zerk type lubrication fittings
on the tie-

rod
and
center link ball-stud ends
• Lubricate
the
ball studs with MOPAR®Multi-Mile- age Lubricant
• Wipe
the
excess lubricant from
the
exterior sur­
faces
of the
ball joints
page

Power
Brake System
30
Power
Steering System
. . 29

Rear
Wheel Bearings
30

Speedometer Cable
33

Steering Linkage
28

Tires
32

FRONT
SUSPENSION
BALL JOINTS

INSPECTION When
a
vehicle
is
raised
for
lubrication/general
maintenance,
the
ball joints should
be
inspected.
LUBRICATION SCHEDULE The front suspension ball joints
are
lubricated dur­
ing manufacture with
a
long-life chassis lubricant.
However,
it is
recommended that
the
ball joints
be

inspected
and the
studs lubricated:
•
At
each
36 000 km
(22,500 miles) interval
or
every
2 years,
for
vehicles subject
to the
LIGHT DUTY
CY­
CLE Maintenance Schedule
•
At
each
9 600 km
(6,000 miles) interval
or
every
2

years,
for
vehicles subject
to the
HEAVY DUTY
CY­
CLE Maintenance Schedule.
4WD vehicles that
are
frequently driven
off-

road should
be
lubricated
at
every engine
oil
change.
LUBRICATION (1) Inspect
the
front suspension. Examine
the
ball
studs
for
looseness
and
excessive wear. (2) Replace
all
torn ball-stud seals
and
damaged
ball joints. Damaged seals should
be
replaced
to
pre­ vent leakage
and
contamination.

CAUTION:
Use
care
to
prevent lubricant from
con­

tacting
the
brake rotors.

(3) Lubricate
the
ball studs:
• Clean
the
Zerk type lubrication fittings
on the

ball-stud ends
• Lubricate
the
ball studs with MOPAR®Multi-Mile-age Lubricant
• Wipe
the
excess lubricant from
the
exterior sur­
faces
of the
ball joints

MANUAL
STEERING
GEAR

LUBRICATION Manual steering gears
are
permanently lubricated
during manufacture. Periodic lubrication
is not
nec­
essary.

0
- 32
LUBRICATION
AND
MAINTENANCE

•

Fig.
5 Parking Brake Ratio Lever Lubrication (2) Note any indication of brake overheating,
wheel dragging or the vehicle pulling to one side.
(3) Evaluate any performance complaints received
from the owner/operator. (4) Repair the brake system as necessary (refer to
Group 5—Brakes for additional information and ser­
vice procedures).

BODY
COMPONENT
MECHANISMS
LUBRICATION REQUIREMENTS
All operating mechanisms and linkages should be
lubricated when necessary. This will maintain ease of operation and provide protection against rust and
excessive wear. The door weatherstrip seals should
be lubricated to prolong their life as well as to im­ prove door sealing.

LUBRICANT SPECIFICATIONS
All applicable exterior and interior vehicle operat­
ing mechanisms should be:
• Inspected • Cleaned
• All the pivoting/sliding contact areas on the mech­ anisms should then be lubricated.
MOPAR®Multi-Mileage Lubricant or an equiva­
lent, should be used to lubricate the mechanisms.
The door weatherstrip seals should be lubricated
with silicone lubricant spray. Refer to the Body Lu­
bricant Specifications chart below for additional lu­
bricant applications.

LUBRICATION
(1) When necessary, lubricate the cab and cargo
box operating mechanisms with the specified lubri­
cants.

(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray that can soil pas­
senger clothing. (3) Before applying lubricant, the component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The hood latch, latch release mechanism, latch
striker and safety latch should be lubricated periodi­
cally.
(5) The door lock cylinders should be lubricated 2
times each year (preferably autumn and spring): • Spray a small amount of lock cylinder lubricant di­
rectly into the lock cylinder
• Apply a small amount to the key and insert it into
the lock cylinder • Rotate it to the locked position and then back to
the unlocked position several times
• Remove the key. Wipe the lubricant from it with a
clean cloth to avoid soiling of clothing.

TIRES
RECOMMENDED MAINTENANCE
The condition of the tires should be inspected. The
inflation pressures tested/corrected at the same time as the engine oil is changed and the oil filter is re­
placed.
The tires/wheels should be rotated periodically to
ensure even tread wear. The tires/wheels should be
rotated at the first 12 000 km (7,500-miles) interval.
Thereafter, at each 24 000 km (15,000-miles) inter­
val.
INSPECTION
Inspect the tires for excessive wear, damage. Test
the tires for the recommended inflation pressure and adjust the pressure accordingly. Refer to the tire in­
flation pressure decal located on the left door face. Also to Group 22—Tires And Wheels for tire pres­sure charts, tire replacement, and treadwear indica­

tors.

ROTATION
Tires/wheels should be rotated according to the rec­
ommended interval. The first tire/wheel rotation is
the most important for establishing the prevention of uneven tread wear. After rotation, adjust the tire in­
flation pressure to the air pressure recommended on
the decal located on the left door face.
Refer to Group 22—Tires And Wheels for the rec­
ommended method of tire/wheel rotation.

HEADLAMPS

MAINTENANCE SCHEDULE
Every six months check the headlamp beams to en­
sure that the headlamp beams are correctly posi­
tioned.

AIM
ADJUSTMENT
Refer to Group 8L—Lamps for headlamp aim ad­
justment procedures.

FRONT SUSPENSION
AND
AXLE
2 - 3

FRONT
WHEEL
ALIGNMENT

GENERAL
INFORMATION
Front wheel alignment involves
the
correct posi­
tioning
of the
tire contact patch
in
relation
to the

pavement.
The
positioning
is
accomplished through
the suspension
and
steering linkage adjustments.
An
alignment
is
essential
for
efficient steering
and
direc­
tional stability.
The
most important factors
of
front
end alignment
are
camber, caster
and toe
position. Routine inspection
of
the front
suspension
and
steering components
is a
good
preventative

maintenance practice.
Inspection
also
helps
to
ensure
safe operation
of the
vehicle.

• CAMBER
is the
number
of
degrees
the top of the

wheel
is
tilted either inward
or
outward.
An
excessive
negative camber angle will cause tread wear
at the in­
side
of
the tire.
An
excessive positive camber angle will
cause tread wear
at the
outside
of
the tire (Fig.
1),
• CASTER
is the
number
of
degrees
of
forward
or

rearward tilt
of the
steering knuckles. Forward tilt
provides
a
negative caster angle. Rearward tilt pro­ vides
a
positive caster angle
(Fig. 1).

• WHEEL
TOE
POSITION
is the
difference between
the leading
and
trailing inside edges
of the
front
tires (Fig.
1).
Incorrect wheel
toe
position
is the
most common cause
of
unstable steering
and
steering wheel off-center.
The
wheel
toe
position
is the
final
front wheel alignment adjustment. • STEERING AXIS INCLINATION ANGLE
is
mea­
sured
in
degrees
and is the
angle that
the
steering
knuckles
are
tilted (Fig. 1).
The
inclination angle
has

a fixed relationship with
the
camber angle. This will
not change except when
a
spindle
or
ball stud
is

damaged
or
bent.
The
angle
is not
adjustable
and the

damaged component(s) must
be
replaced
to
correct
mis-alignment.

CAUTION:
Do not
attempt to modify
any
suspension

or steering
component
by
heating
and
bending.

PRE-ALIGNMENT INSPECTION
Before starting
a
front wheel alignment,
the
follow­
ing inspection
and
necessary corrections must
be
completed.
(1)
Tires with
the
same recommended
air
pressure,

size,
and
tread wear. Refer
to
Group
22,
Wheels
and

Tires
for
diagnosis information. (2) Front wheel bearings
for
wear
or
adjustment.
(3) Ball studs
and
linkage pivot points, steering
gear
for
looseness, roughness, binding
or a
sticking
condition. Refer
to
Group
19,
Steering
for
additional information.
CASTER

POSITIVE CASTER
STEERING
WHEEL CENTER

i 0.5
CCW
0
5
CW

CCW
=
COUNTER CLOCKWISE
CW
-
CLOCKWISE
CAMBER

NEGATIVE CAMBER (SHOWN)
TOP
OF
WHEEL INBOARD
POSITIVE CAMBER
(NOT
SHOWN)
TOP
OF
WHEEL OUTBOARD
NOMINAL-PREFERRED

THE NOMINAL VALUE
IS

THE
PREFERRED
VALUE

LEFT/RIGHT
DIFFERENCE

THE VALUE
Of
THE LEFT SIDE
MINUS THE VALUE
OF
THE
RIGHT SIDE

EX.

If
FT CASTER
- +6 5

RIGHT
CASTER
»
+8.0

LEFT/RIGHT DIFFERENCE

65 8.0
=
1
5
TOE

NEGATIVE TOE (TOE
OUT)
B>A
POSITIVE TOE (TOE
IN) 6<A
FRONT
Of
VEHICLE
ft
THRUST
ANGLE

ANGLE
OF
REAR
AXLE RELATIVE
TO
VEHICLE CENTERUNE

(+)
AXLE POINTS LEFT
(-)
AXLE POINTS RIGHT

PRODUCTION
TOLERANCE
THE RANGE
Of
ACCEPTABLE

VALUES
AROUND THE NOMINAL

-
PREFERRED PRODUCTION
+6.5A7.5

PREFERRED:
+7.0

TOLERANCE:
0.5
J9302-61

Fig.
1
Wheel
Alignment
Measurements

•

FRONT
SUSPENSION
AND
AXLE
2 - 5 (4) Front wheels for excessive radial, lateral
runout and unbalance. Refer to Group 22, Wheels and Tires for diagnosis information.
(5) Suspension components for wear and noise. Check
components for correct torque. Refer to Groups 2 and 3, Suspension and Axle for additional information.

WHEEL
ALIGNMENT
MEASUREMENTS/ADJUSTMENTS
The front wheel alignment positions must be set to
the specified limits. This will prevent abnormal tire
tread wear. The equipment manufacturer&#39;s recommenda­
tions for use of their
equipment
should always
be followed. All
damaged
front suspension sys­
tem components
should
be replaced. Do not at­ tempt to straighten any
bent
component.

CAMBER AND CASTER-2WD VEHICLES Camber and caster angle adjustments involve repo­
sitioning the upper suspension arm cam adjustment
bolts (Fig. 2). Alignment adjustments are accom­
plished by loosening the nuts and changing the posi­
tion of the cam bolt.
(1) Remove all foreign material from the adjust­
ment bolt threads.
(2) Record the camber and caster measurements
before loosening the adjustment bolt nuts.
(3) The camber angle should be adjusted as near as
possible to the preferred angle. The caster should be
the same at both sides of the vehicle. Refer to the Specifications chart.
CAMBER AND CASTER—4WD VEHICLES For 4WD vehicles, the correct wheel camber (verti­
cal tilt) angle is factory preset at zero degree (0°).
Camber cannot be altered by adjustment.
CAUTION: Do not attempt to
adjust
the
camber
an­
gle by
heating
or bending the axle or any
suspen­

sion
component. If camber angle is
incorrect,
the
component(s)
causing
an
incorrect
angle must be replaced.
(1) It is important that the camber (vertical tilt)
angle be the same for both front wheels.
(2) The camber angle should be measured with ac­
curate wheel alignment equipment. The acceptable
range is -1° to +1°. Refer to the Specifications chart.
Road test the vehicle and observe the steering
wheel return-to-center position. Before road testing,
check
and
correct
the tire
inflation pressures. Inflate
both
of the front tires
with exactly the
same
pressure.
During the road test, make vehicle turns to both
the left and right. If the steering wheel returns to­
ward the center position unassisted, the caster angle is correct. However, if the steering wheel does not re­ turn toward the center position unassisted, an incor­
rect caster angle is probable.
(1) The caster angle is factory preset at positive
two degrees
(
+
2°).
The acceptable range is +1/2° to +
3
1/2°.
(2) The caster angle should be measured with ac­
curate wheel alignment equipment.
(3) Caster angle can be adjusted by installing ta­
pered shims between the front axle pads and the spring brackets. The caster angle should be adjusted
as near as possible to the preferred angle.
(4) Record the caster measurement before remov­
ing the original shims from the spring pads.
(5) The caster should be the same at both sides of
the vehicle. Refer to the Specifications chart.
RN1030

Fig.
2 Caster &
Camber
Adjustment Location—2WD
Vehicles

WHEEL TOE POSITION The wheel toe position adjustment should be the fi­
nal front wheel alignment adjustment. In all in­ stances, follow the equipment manufacturer&#39;s
recommended procedure.
(1) Secure the steering wheel with the front wheels
in the straight-ahead position. For vehicles equipped
with power steering, start the engine before straight­ ening the wheels.
With power steering, the engine should be op­
erating during the wheel toe position adjust­
ment.
(2) Loosen the tie rod adjustment sleeve clamp
bolts (Fig. 3).
(3) Adjust the wheel toe position by rotating the
tie rod adjustment sleeve (Fig. 3). Rotate each tie-rod end in the direction of
sleeve rotation during the adjustment (Fig. 3).
This will ensure that both tie-rod ends are at the center of their travel.
(4) If applicable, turn the ignition switch off.

2
- 10
FRONT SUSPENSION
AND
AXLE

• INSTALLATION
(1) Position the spring and isolation pad on the
suspension arm. Install the spring compressor tool.
Compress the spring until the lower suspension arm
can be properly positioned in the steering knuckle.
(2) Install the nuts on the ball studs. Tighten the
upper nut to 142 Nnn (105 ft. lbs.) torque. Tighten
the lower nut.
* 11/16-16 bolt, to 183 Nnn (135 ft. lbs.) torque
• 3/4-16 bolt, to 237 Nnn (175 ft. lbs.) torque Install replacement cotter pins.
(3) Install the strut.
(4) Connect the stabilizer bar.
(5) Install the shock absorber.
(6) Install the brake splash shield on the steering
knuckle. Tighten the screws to 23 Nnn (200 in. lbs.)
torque.
(7) Carefully install the hub/rotor and bearings.
(8) Install the brake caliper, refer to Group 5, Brakes.
(9) Install the wheel and tire, refer to Wheel and Tire
Installation within this section. Lower the vehicle. (10) Test the vehicle brakes and the suspension for
proper operation.

LOWER SUSPENSION
ARM
REMOVAL
(1) Follow procedure under Coil Spring Removal.
(2) Remove hex-head mounting bolt from the cross-
member. (3) Remove the lower suspension arm from vehicle.
INSTALLATION (1) Position lower suspension arm on vehicle.
(2) Install mounting bolt, tighten finger-tight.
(3) Follow procedure under Coil Spring Installa­
tion.
(4) Lower the vehicle to the surface with the
wheels/tires supporting the vehicle weight. Tighten
the lower suspension arm mounting bolt to 305 Nnn (225 ft. lbs.) torque.

LOWER
BALL
STUD

INSPECTION
(1) Raise the front of the vehicle. Install safety
floor stands under both lower suspension arms as far outboard as possible. The upper suspension arms
must not contact the rebound bumpers. (2) Install a dial indicator and clamp assembly to
the lower suspension arm. (3) Position indicator plunger against knuckle arm
and zero indicator. (4) Raise and lower the wheel with a pry bar under
the center of the tire. Measure the axial movement of
the knuckle with respect to the suspension arm.
(5) If the travel of the suspension arm is 0.020
inch (0.51 mm) or more, replace the ball joint. REMOVAL
(1) Follow procedure under Coil Spring Removal.
(2) Remove ball joint seal. Use assembled Remov­
er/Installer C-4212 to force the ball stud out of the
lower suspension arm bore (Fig. 6).

Fig.
6
Lower
Bail
Stud
Removal

INSTALLATION (1) Force the replacement ball stud into the lower
suspension arm bore with assembled Remover/In­
staller C-4212 (Fig. 7).
Fig.
7
Lower
Ball
Stud
Installation

•

FRONT
SUSPENSION
AND
AXLE
2 - 15 Ensure the shock absorber is positioned on the
stud with retainers correctly located (Fig. 2).
(2)
Position the inner retainers on the mounting

studs.

(3) Install the shock on the upper and lower stud
and install the outer retainers.
(4) Install the nuts on the frame bracket and axle
(Fig. 2). (5) Tighten the shock absorber upper and lower

nuts;
• Standard shock upper and lower nut to 75 Nnn (55
ft. lbs.) torque
• Air-adjustable shock upper nut to 75 N»m (55 ft. lbs.) torque, lower nut to 271 Nnn (200 ft. lbs.)
torque

CAUTION:
Vehicles
with
air
shocks MUST
maintain

a
minimum
pressure
of 10 to 15 psi (70 to 105 kPa). Operation below the specified minimum
pressures
may cause damage.

(6) Remove the supports and lower the vehicle.

LEAF
SPRINGS
REMOVAL
(1) Raise and support the frame until all weight is
removed from the front springs. (2) With the front tires in contact with the surface,
position support stands under the frame side rails. (3) Remove the nuts, lockwashers, U-bolts that at­
tach the spring to the axle shaft tubes (Fig. 3).
SPRING
BRACKET SPRING
BRACKET SPRING
SHACKLE
PLATE
FRONT
SPRING
AXLE
TUBE U-BOLT LEFT
SIDE

J9017-33

Fig.
3 Front
Suspension
(4) Remove the spring front eye pivot nut and bolt,
rear spring shackle nuts, shackle plates. Remove the spring from the vehicle (Fig. 3).
INSTALLATION

(1) Align the spring front eye with the bolt hole in
the frame bracket and install the pivot bolt and nut (Fig. 3). (2) Position the shackle plates at the spring rear
eye and frame rail bracket. Install the nuts (Fig. 3). (3) Tighten the shackle plate nuts and front pivot
bolt nut until all slack is taken up. (4) Position the spring on the axle tube with the
spring center bolt seated in locating hole in axle tube
pad (Fig. 3).
(5) Install the U-bolts, new lockwashers and nuts.
(6) Tighten the nuts snug against the spring
bracket.
(7) Remove the supports and lower the vehicle
with the weight being supported by the tires. (8) Tighten the spring nuts according to the follow­
ing specifications:
• Model 44 Axle: U-bolt/Stud nuts - 115 Nnn (85 ft. lbs.) torque
Front pivot bolt/nut — 135 Nnn (100 ft. lbs.) torque
Rear shackle bolt/nut — 81 Nnn (60 ft. lbs.) torque
• Model 60 Axle: U-bolt nuts - 129 Nnn (95 ft. lbs.) torque Front pivot bolt/nut - 135 Nnn (100 ft. lbs.) torque
Rear shackle bolt/nut - 108 Nnn (80 ft. lbs.)
torque

SPRING LEAF-REPLACEMENT
If a spring has acquired a set (lost significant
height), it should be replaced. (1) Remove the spring from the vehicle. If neces­
sary, refer to the removal procedure. (2) Remove the spring leaf alignment clips.
(3) Clamp the spring in a vise. Remove the nut
and center bolt (Fig. 4).
SPRING

CENTER
RATCHET
AND

SOCKET

WRENCH

Fig.
4 Leaf
Spring
Disassembly
(4) Insert a long drift or punch into the center bolt
hole and slowly release the vise jaws.